Model-Based Commissioning of Systems and Processes

The commissioning of complex fully automated systems for realizing complete process chains represents the last step in order to establish functioning of such a system. Novel process chains for manufacturing composite structures are subject to continuous change and therefor create divergent and changing requirements for commissioning. Furthermore the multidisciplinarity between mechanical, electrical and electronic system components is a general trend. Model-based interdisciplinary tools and methods exist for assisting commissioning, and data from process simulation are often available for the highly complex and novel processes. However, these methods are not consistently applied, and there is no integrative use with feedback from the initial operation. On the one hand this leads to unscheduled delays, and on the other hand the systems are operated in a suboptimal manner regarding productivity, accuracy and energy efficiency. This contribution demonstrates how integrative mechatronic models and data from process simulation can be flexibly designed and used according to the requirements of the commissioning of these new and flexible systems. The models serve as virtual prototypes, offering the potential to gain deeper understanding of the system even before its final assembly and considerably shorten the commissioning process. At the same time it becomes possible to determine possible optimal parameters for automation and control. By developing and documenting the model, the proceeding towards the final parameter adjustments becomes transparent. Using a specific example, the contribution shows the continuous approach of process chain simulation, system design, initial system operation and system optimization.